Materials comprising textile debris and latex based binder

ABSTRACT

A composite material having physical characteristics equivalent to particle board materials bonded with resin-based adhesives that contain formaldehyde-urea is formed of reclaimed textile debris comprising fabric scraps and a latex based binder. The binder includes natural rubber latex, sulfur, an anti-oxidant agent and pH adjustment substances. The binder may also include selected amounts of zinc oxide, zinc diethyldithiocarbamate and a stabilizer. Production of the composite material includes mixing the constituents and vulcanization through the application of heat and compression. Cold compression is subsequently applied.

BACKGROUND OF THE INVENTION 1. Field of the Invention

This invention relates generally to composite materials formed of atextile debris mixture and more specifically to materials wherein atextile debris mixture is bonded with adhesives made from natural rubberlatex.

2. Antecedents of the Invention

Millions of tons of fabric fiber and textile waste have been dumped eachyear. Rag is a type of solid waste that is difficult to degrade,produces carbon dioxide if burned as fuel and does not readily decomposein a landfill. Although small amounts of fabric fiber and textile havebeen reused or recycled as stuffing in furniture or dolls, etc., onlybiodegradable natural fibers are suitable as fuel or landfillreclamation, etc., while manmade fiber constituents of textile debriscontribute to toxic pollution.

In the past, adhesives containing formaldehyde-containing resin wereused as a binder for recycling materials such as rubber wood, pine, etc.in order to use wood chips and scrap in furniture and other products.

Thai patent application No. 1301002135 revealed a plywood material madefrom thin rubber wood slabs reinforced with layers of glass fiber clothby using epoxy adhesives containing silane compounds between layers andpressed to compress with heat and pressure as specified.

Thai Patent No. 7451, (request No. 1103000520) by Miss PrindaTaevijitsilp, entitled: Sheets By Waste Materials disclosed themanufacture of compressed sheets from debris materials, such as plantleaves, rubber foam, plastic scrap as well as rag, by using polymeradhesives such as diphenyl methane diocyanate or urea adhesives asmelamine formaldehyde plus heat. The debris material and formaldehydeadhesive was compressed into the sheets for use in lieu of wood.However, formaldehyde-urea adhesive has a high vapor evaporation rate.As a result the environment and consumers have been exposed to toxicfumes both in the production process and in the form of finishedproducts.

As a result, attempts have been made to use a binder made from naturaland non-hazardous materials such as rubber or latex. The binder wasmixed with textile debris materials and the mixture compressed with heatto obtain non-toxic material. Inorganic additives such as calcium,silica or alumina, catalysts, stimulants, hardness and mechanicalstrength additives, color pigments and flame retardants, etc. have beenadded to increase the physical and mechanical properties of compositematerials.

Thai Patent application No. 100274, (request No. 0701000589), entitled:Formula, Material and Production Process of Natural Rubber Mixed WithWood Sawdust by Siam United Rubber Co., Ltd., King Mongkut's Universityof Technology Thonburi and the Office of Research Fund disclosed woodsawdust powder mixed with natural rubber and various additives such as aflame retardant, etc. to adjust the properties of the product. Themixture was hot extruded into the roofs and coated with urethane.

Thai Patent application No. 131263, (request No. 0901004008, entitled:Sheet-making Process From Fabric by Mr. Yuttana Anothaisintaveedisclosed a method wherein fabric debris is chopped into rough pieces,size 1-15 square centimeters, then remove the rag that has been mixedwith PMDI (Polymeric Diphenyl Methane Di-isocyanate) and adjust theproperties with other substances such as flame retardants,moisture-resistant substances, etc. The mixture is then formed intosheets by mechanical methods including placement into molds andcompression under heat to form composite sheets. The isocyanateconstituent of the PDMI is an inorganic substance that is volatile anddifficult to degrade. The vapor of this type of glue is toxic to therespiratory system, harmful to the user, the environment and the worker.

Rubber or latex is a natural substance that contains proteins making iteasy to degenerate. Rubber is a non-polar substance while fiber debrisand adhesives are polar substances. Heretofore, when fiber debris wasbonded with adhesives containing rubber, weak mechanical bondingresulted between the adhesives and the fabric fibers. In addition, thereexisted the problem of infiltration (wettability) between the rubber orlatex based binder and any inorganic additives as well as between rubberand the fabric fibers. As such, the use of rubber as a binder did notresult in a stable strong composite material.

U.S. Pat. No. 6,127,476 entitled: Aqueous Rubber Composition, disclosedadhesives containing carboxylate latex, which are made from naturalrubber latex, styrene, butadiene, unsaturated monomer acid, sulfur and acatalyst for binding a rubber substrate to fabric. According to thispatent, adhesives do not contain hydrocarbon solvents or tackifiers andhave the high peel resistance. While the adhesives were suitable for usewith bonding rubber sheets or rubber to fabric, such as the manufactureof tennis balls, etc., but the adhesives were not suitable for use withinterlocking composite materials that require high strength anddurability.

From the foregoing disadvantages, it can be seen that there is the needto provide composite materials having high strength and durability froma mixture of textile debris and an environmentally sound binder as wellas methods of producing such materials.

SUMMARY OF THE INVENTION

A composite material is fabricated from textile debris such as fabricscraps, fabric fibers and a binder comprising natural rubber latex andsulfur in the amount sufficient for vulcanization together with zinc, ananti-oxidant agent, zinc oxide, a stabilizing agent and pH adjustmentsubstances. The production of such composite material employs heat andcold compression, which results in a material having physical propertiesequivalent to particle board materials fabricated with resin-basedadhesives that contain formaldehyde-urea.

From the foregoing compendium it will be appreciated that an aspect ofthe present invention is to provide composite materials of the generalcharacter described which are not subject to the aforementioneddisadvantages of the antecedents of the invention.

A feature of the present invention is to provide composite materials ofthe general character described having high strength and durabilitycomprising a mixture of textile debris and a natural rubber latexbinder.

A consideration of the present invention is to methods for producingcomposite materials with high strength and durability using naturalbinders that are less toxic to the environment than formaldehyde-ureabinders.

Another aspect of the present invention is to provide compositematerials of the general character described including

Textile debris; and binders that are combined with:

Natural rubber latex 100 parts Sulfur 0-1.0 parts Zincdiethyldithiocarbamate 0-1.0 parts Antioxidant 0.1-1.0 parts Zinc oxide(ZnO) 0-5.0 parts Stabilizer 0-1.0 parts and pH adjustment substance0.1-1.0 parts

In addition, stabilizing substance in adhesives may be selected fromderivatives of amines and phenols either or combining.

Composite materials, which the adhesives are included with color pigmentfillers, magnesium oxide and fillers, may be selected from groups ofcalcium carbonate, titanium dioxide, silica, synthetic fibers andnatural fibers either or combining.

In addition, stabilizing substance may be potassium laurate (K-laurate)and pH adjustment substance may be potassium hydroxide (KOH).

The fabric fibers may be combined with fabric fibers that are choppedinto small pieces with fiber lengths in the range (a) 0.5-1.0 cm, (b)1.0-2.0 cm and (c) 2.0-3.0 cm with fiber ratio (a): (b): (c) equal to 1:1 : 1 to 1: 2: 4.

Another feature of the present invention is to provide compositematerials of the general character described including textile debris;and binders that are combined with:

Natural rubber latex (30-65% rubber) 100 parts Sulfur 0-1.0 parts Zincdiethyldithiocarbamate 0-1.0 parts Lovinox ® (CPL) 0-2.0 parts Zincoxide (ZnO) 0-5.0 parts Titanium dioxide (TiO2) 0-10.0 parts Potassiumlaurate (K-laurate) 0.1-1.0 parts and Potassium hydroxide (KOH) 0.1-1.0parts

A further consideration of the present invention is to provide a methodof producing composite materials of the general character describedincluding:

-   -   Preparation of textile debris with the size and shape according        to the specified proportion in advance;    -   Mixing of textile debris and binder together with the preset        ratio in advance with blender at speed of 10-30 rounds per        minute for 5-20 minutes;    -   Making the mixture of textile debris and binder crosslink in the        mold under the pressure of 3,000 to 6,000 psi at temperatures of        80-180 ° C. for 10-30 minutes;    -   Pressing the mixture of textile debris and binder in the mold by        the cold press machine with compressive strength between        3,000-6,000 psi for 60-360 minutes; and    -   Removing composite materials from molds

Yet another aspect of the present invention is to provide a method ofproducing composite materials of the general character describedincluding:

Preparation of textile debris with the size and shape according to thespecified proportion in advance

Mixing of textile debris and binder together with the ratio of binder totextile debris 10-60% by weight with blender at speed of 10-30 roundsper minute for 5-20 minute;

Reducing moisture of the good blending of textile and binder to 0-5%moisture content by heating process between a temperature of 40-70degrees Celsius;

Mincing the dried ingredients from the previous step into small pieceswith different fiber lengths in the range (a) 0.5-1.0 cm, (b) 1.0-2.0 cmand (c) 2.0-3.0 cm;

Mixing the ingredients (a), (b) and (c) that have been minced from theprevious step with the proper ratio to control the fibers dispersion andadhesion with the proportion ratio (a): (b): (c) in the range between 1:1: 1 to 1: 2: 4;

Making the mixture of textile debris and binder crosslink in the moldunder the pressure of 3,000 to 6,000 psi at temperatures of 80-180 ° C.for 10-30 minutes;

Pressing the mixture of textile debris and binder in the mold by thecold press machine with compressive strength between 3,000-6,000 psi for60-360 minutes; and

Removing composite materials from molds

In addition, the composite materials production process may also beincluded the composite materials cutting process to the desired size andthe composite materials improving surface, too.

Other aspects, features and considerations of the present invention inpart will be obvious and in part will be pointed out hereinafter.

With these ends in view, the invention finds embodiment in variouscombinations of elements, arrangements of parts and series of steps bywhich the above-mentioned aspects, features and considerations andcertain other aspects, features and considerations are attained, allwith reference to the accompanying drawings and the scope of which willbe more particularly pointed out and indicated in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, wherein some of the various possibleexemplary embodiments of the invention are shown:

FIG. 1 comprises a flow chart of the composite materials productionprocess in one embodiment of the invention; and

FIG. 2 comprises a flow chart of the composite materials productionprocess in a second embodiment of the invention.

DESCRIPTION OF THE INVENTION

Description about this invention will be done by providing examples ofthe invention and referred by using the figures as the examples to makethe clearer description. The same parts in these figures are representedby the same reference number which is not limited in any way and thescope of the invention will follow the rights attached at the end.

According to FIG. 1 that shows the composite materials productionprocess from textile which consists of the following steps:

Fabric Fiber Preparation (S101-S102)

In the process of S101, the collection of textile waste in the form ofused fabric or fabric from the garment manufacturing industry isseparated to the fiber and the non-fiber parts, especially metalaccessories such as buttons or metal/plastic zipper from the fabrics byusing the metal separator device or manual sorting.

In the process of S102, the textile fibers are minced into small pieceswith different fiber lengths in different groups, i.e. group (a) 0.5-1.0cm, group (b) 1.0-2.0 cm and group (c) 2.0-3.0 cm.

Mixing Fibers and Adhesives (S104)

Fibers of group (a), (b) and (c) are mixed at the appropriate ratio tocontrol the fibers dispersion and adhesion which determines thehardness, bending strength and the final product quality consistency.Examples of the appropriate fiber ratio (a), (b) and (c) are 1:1:1 to1:2:4.

The fiber mixture is then placed in a rotary blender and 10-60%bio-natural rubber adhesion by weight is added, depending on thethickness and properties of the composite material from the desiredtextile.

An example of a binder made from bio-natural rubber latex includes:

Proportion per 100 Ingredients rubber volume (PHR) Natural rubber latex(30-65% rubber) 100 Sulfur  0-1.0 Zinc diethyldithiocarbamate (ZDEC)0.1-1.0 Lovinox 8, CTPL is an antidegradant 0.1-2.0 Zinc oxide (ZnO) 0-5.0 Titanium Dioxide (TiO2) (Option)  1.0-10.0 Potassium laurate(K-laurate) is a stabilizer 0.1-1.0 Potassium hydroxide (KOH) is a PHregulator 0.1-1.0 * PHR—Part per Hundred Rubber is the amount ofchemicals compared to 100 natural rubber.The natural rubber latex used should have rubber content in the range30-65%

Sulfur is a substance that is used to cause the reaction in thevulcanization process which will help prevent latex from dissolving inorganic solvents by making the natural rubber cross-linking up in thestructure and will help increase the condition of wettability betweennatural rubber and the original inorganic substances and fabricfibers/textile scraps. The infiltration conditions can be adjusted byreducing the amount of sulfur as well as changing the mixing parameterssuch as stirring speed, time and temperature.

Anti-degeneration agents can be selected from (but not limited to)groups that comprise either or in combination of amine derivatives,phenols and phenol derivatives.

Amine derivatives, such as N-isopropyl-N-“phenyl-p-phenylenediamine,N-413-dimethylbutyl-N″″ phenylp-phenylenediasmine,2,2,4-Trimethyl-1,2-dihydroquinoline, and etc.

Phenol derivatives, including 2,6 Di-tert-bytyl (-p-cresol), (poly(dicyclopentaclient-co-peresol),4,4′-bytylidene-bis-(2-tertarylbutyl-5-methylphenol), and etc.

Lovinox® is the trademark of the product of Addivant USA LLC and thechemical name is phenol, 4-methyl, which is the result of reactivationwith dicyclopentadiene and isobutene

Metal oxide can be either or combination of zinc oxide, magnesium oxide

Filler for adding properties of composite materials, including either orcombination of calcium carbonate, titanium oxide, silica, syntheticfiber and/or natural fibers.

Titanium oxide, when mixed with natural rubber latex, will make thelatex white. It can be used as needed.

A polymeric binder material, such as polyurethane water-based binderand/or acrylic water-based binder in the ratio of 10-70 parts per 100natural rubber latex parts may be added as a binder. The polymericbinder material strengthens the bond and promotes vulcanization withreduced or no sulfur.

To ensure that the mixed ingredients are consistent, the speed androtation time of the blender should be in the range of 10-30 revolutionsper minute with duration of 5-20 minutes.

Crosslinking (S105)

After the mixture is mixed together with the fiber and binder of naturalrubber, it is placed into a mold conforming to the size and shape of thedesired product in a hot press machine. By controlling the pressure,temperature and duration crosslink between the fabric fibers and thebinder can be achieved. The mixture should be compressed within a rangeof 3,000 to 6,000 psi at a temperature of 80-180 degrees Celsius for10-30 minutes.

Cold Pressing (S106)

To ensure that the adhesion reaction and maintain the hardness andthickness of the product are in accordance with a specified standard,the hot-pressed molded pieces are repressed in a cold press machine witha compressive force between 3,000-6,000 psi for a period of 60-360minutes.

Final Finishing (S107)

The cold pressed molded pieces of composite material are removed fromthe mold and cut to a desired size and trimmed. Other finishingprocedures may be employed, such as, smoothing surfaces.

Examples of composite materials based on the above production processeshave been tested for bending strength by methods according to ASTM D790,the strength of tightening by means of ASTM 1037, density by methodaccording to ASTM D297, thermal conductivity by ASTM C518 standardmethod and Hardness Shore A by ASTM D2240 standard method.

The second embodiment of the invention resides in the inventor'sdiscovery that modifying the process by mixing the binder with thetextile scraps and then drying the textile scraps soaked with the binderuntil the moisture content is 5% or less before chopping to the size andshape as specified, makes the mixture of textile scraps and binder moreconsistent than mixing chopped scraps directly with the binder. Themethod depicted in FIG. 2 reduces the problem of scraps stickingtogether, resulting in uneven distribution and dispersal of the textilescraps as they absorb the binder, causing the scraps sticks together insmall pieces which requires a lot of time to mix and which consumes moreenergy in agitation in order to make the textile scraps to absorb thebinder thoroughly until each group of textile scraps has a uniformdistribution that is homogeneous.

FIG. 2 illustrates the process of producing composite sheet materialsfrom textiles which comprising of the following:

Fabric Fiber Preparation (S201-S203)

As illustrated at S201, the textile scraps in the form of used fabric orfabric obtained from apparel production industry are collected. Then,the fiber and non-fiber components are separated. Metal accessories suchas buttons or metal/plastic zippers are removed from the fabric by usinga magnetic separator or manual sorting.

In step S202, fiber and binder which has the main ingredient made fromnatural rubber latex are blended. The binder should have sufficientliquid to ensure that the fibers are thoroughly soaked with the binder.This can be achieved by spinning in a rotary blender as well as byadding 10-60% of bio natural rubber latex binder 10-60%, depending onthe thickness and desired properties of the textile composite board. Toensure that the mixture is consistent, the speed and rotation time ofthe blender should be in the range of 10-30 revolutions per minute for5-20 minutes.

In step S203 the moisture content of the mixed ingredients is reduced to05% by heating. For example, drying naturally under the sun or wind orbaking with a hot air oven or something similar within the temperaturerange of 60-100 degrees Celsius, etc., until the moisture content fallswithin the specified range.

Digesting Binder-Containing Fibers (S204)

In step S204, the textile fibers that are coated with binder and aredried are digested or chopped and separated into small pieces withdifferent fiber lengths in different groups, i.e. group (a) 0.5-1.0 cm,group (b) 1.0-2.0 cm and group (c) 2.0-3.0 cm.

Mixing Binder-Containing Fibers trhat have Been Digested (S205)

Step S205 involves mixing group (a), (b.) and (c) fibers in theappropriate ratio to control the dispersion and adhesion of fibers whichdetermines the hardness, strength and quality, and consistency of thefinal product. An example of an appropriate ratio of group (a), (b) and(c) fibers is between 1:1:1 to 1:2:4.

Crosslinking in the Mold (S206)

The mixture is then it is placed into a mold conforming to the size andshape of the desired product in a hot press machine. By controlling thepressure, temperature and duration, complete crosslinking between thefabric fibers and the binder can be achieved. The mixture should becompressed within a range of 3,000 to 6,000 psi at a temperature of80-180 degrees Celsius for 10-30 minutes.

Cold Pressing (S207)

To ensure that the adhesion reaction and to maintain the hardness andthickness of the product to meet specified standards, the hot-pressedwork pieces are re-pressed through at cold press process in a cold pressmachine using compressive strength between 3,000-6,000 psi for a periodof 60-360 minutes.

Final Finishing (S208)

The cold pressed molded pieces of composite material are removed fromthe mold and cut to a desired size and trimmed. Other finishingprocedures may be employed, such as, smoothing surfaces.

Composite materials obtained according to the methods described aboveare solid and have high strength, can be used as a substitute forplywood or MDF flooring to be used to cover walls, partitions, orfurniture because they can be shaped as needed.

Examples 1 through 6 below illustrate the properties of the compositematerials where the following process and adhere formula are applied.

Proportion per 100 Ingredients rubber volume (PHR) Natural rubber latex100 Sulfur 0.5 Zinc oxide 0.1 Zinc diethyldithiocarbamate 0.1 Lovinox1.0 Titanium Dioxide 0.1 Potassium laurate 0.1 Potassium hydroxide 0.1

Example 1 does not contain of any additional binder such as polyurethaneor acrylic etc. Examples 2-5 contains polyurethane in the proportion of10 parts, 30 parts, 50 parts and 70 parts, respectively. Example 6contains an acrylic binder in the proportion of 70 parts.

Example 1-6 have been done in one layer by extrusion and the materialused is the fine chopped textile scraps mixed with the binder andundergone the drying process and hot press process under the pressure of4000 psi and 100 degree Celsius temperature for 30 minutes and coldpress in the mold with 4000 psi pressure for 100 minutes using themixing ratio and the size of the textile scraps as specified above withthe characteristics as shown in FIG. 3.

The composite materials obtained have a smooth surface. The propertytest of the physical properties of the Examples 1-6 and the controlSpecimen, which is medium density fiber-board (MDF board) and TIS876-2547, which is the industry standard for flat type plywood with thedensity of 400-900 kg/m³ and formaldehyde glue not more than 8 mg/100 g.was used with the thickness 13-20 mm. are shown in the following table.

Test Results

Thermal Shore A Flexural Binding Conduc- Thick- Strength StrengthStrength Density tivity ness (load Example (MPa) (MPa) (kg/m³) (W/m · K)(mm) 1 kg) 1 2.30 0.21 950 0.1638 15 87 2 0.84 0.07 1,055 0.1301 9 69.43 0.91 0.09 1,074 0.1383 9 72.4 4 1.54 0.16 1,091 0.1392 9 82.3 5 4.200.26 1,120 0.1896 9 83.1 6 7.12 0.97 1,079 0.0425 15 83.1 Controlled 200.55 690-770 0.12-0.15 12-19 — MDF Specimen S 876-2547 >13 >0.35 400-900— 13-20 —

Comparison Results

It is found that most Examples had a flexural strength less than 13 MPa,which is lower than the industry standard for general plywood due to thefabric fiber structure and the use of natural rubber latex binder whichhave a tough bonding structure and more flexible than resin-based bindercontaining formaldehyde as the basis. Therefore, such work pieces aresuitable for applications that do not require a lot of strength, but canincrease flexibility or twist well. Thus, it may be suitable forfurniture industrial applications because it can be easily formed intovarious shapes. However, increasing of flexural strength can be done byincreasing the quantity of binder such as polyurethane or acrylic.

In Example 6, the binding strength was 0.95 MPa which is higher than theindustry standard for plywood, which is at 0.35 MPa. In addition, everyExample also exhibited a lower thermal conductivity than general walldecoration materials. In particular, Example 6, which contains anacrylic binder, has a low thermal conductivity, which is close to theheat insulation material used to prevent heat transfer into a building,such as rock wool and thus well suited for use as a thermal insulationmaterial.

It can be seen that composite materials based on fabrication have amixture of textile scraps and binder with the content of natural rubberlatex and artificial materials formed by the inventive method can userecycled materials, resulting in composite materials that are strong anddurable, suitable for use as a replacement of natural wood materials,reducing wood cutting and reduce the waste materials such as fabric,textiles etc. It also contains of less toxic natural binder, thereforeit has low volatile organic compounds (VOC).

The composite materials are therefore suitable for use as furniture andsheet materials for interior and residential decoration.

The particular combinations of elements and features in theabove-detailed embodiments are exemplary only; the interchanging andsubstitution of these teachings with other teachings in this applicationare also expressly contemplated. As those skilled in the art willrecognize, variations, modifications, and other implementations of whatis described herein can occur to those of ordinary skill in the artwithout departing from the spirit and the scope of the invention asclaimed.

Further, in describing the invention and in illustrating embodiments ofthe invention in the figures, specific terminology, numbers, dimensions,materials, etc., are used for the sake of clarity. However the inventionis not limited to the specific terms, numbers, dimensions, materials,etc. so selected, and each specific term, number, dimension, material,etc., at least indudes all technical and functional equivalents thatoperate in a similar manner to accomplish similar purpose. Use of agiven word, phrase, number, dimension, material, language terminology,product brand, etc. is intended to include all grammatical, literal,scientific, technical, and functional equivalents. The terminology usedherein is for the purpose of description and not limitation.

Having described the preferred embodiments of the invention, it will nowbecome apparent to one of ordinary skill in the art that otherembodiments incorporating the concept may be used. Moreover, those ofordinary skill in the art will appreciate that the embodiment of theinvention described herein can be modified to accommodate and/or complywith changes and improvements in the applicable technology and standardsreferred to herein.

Having thus described the invention, there is claimed as new and desiredto be secured by Letters Patent:
 1. A composite material comprisingtextile debris and a binder, the textile debris including fabric scraps,the binder including: natural rubber latex 100 Parts sulfur 0-1.0 Partszinc diethyldithiocarbamate 0-1.0 Parts antioxidant agent 0.1-1.0 Partszinc oxide (ZnO) 0-5.0 Parts stabilizer 0-1.0 Parts and pH adjustmentsubstance 0.1-1.0 Parts.


2. The composite material according to claim 1 wherein the antioxidantagent is selected from the group consisting of amines derivatives,amines, phenols and phenols derivatives, one of them or combined.
 3. Thecomposite material according to claim 1 wherein the binder includes afiller comprising a color pigment.
 4. The composite material accordingto claim 1 wherein the binder further includes magnesium oxide.
 5. Thecomposite material according to claim 1 wherein the binder furtherincludes a filler selected from the group consisting of calciumcarbonate, titanium dioxide, silica, synthetic fibers and naturalfibers, singularly or combined.
 6. The composite material according toclaim 1 wherein the stabilizer comprises potassium laurate.
 7. Thecomposite material according to claim 1 wherein the pH adjustmentsubstance comprises potassium hydroxide (KOH).
 8. The composite materialaccording to claim 1 wherein the textile scraps comprise small pieceshaving fiber lengths in the range of (a) 0.5-1.0 cm (b) 1.0-2.0 cm and(c) 2.0-3.0 cm with fiber ratio (a): (b): (c) is equal to 1:1:1 to1:2:4.
 9. A method producing the composite material according to claim 1comprising the steps of: a) preparing textile scraps from textile debrisby cutting the textile waste into specified sizes; b) mixing the textilescraps and the binder together in a ratio of 10-60% using a blender at aspeed of 10-30 revolutions per minute for 5-20 minutes; c) crosslinkingthe mixture of textile scraps and binder in a mold by applying acompressive force of 3,000 to 6,000 psi at temperature of 80-180 degreesCelsius for 10-30 minutes; d) compressing the mixture of textile scrapsand binder in a cold press with a compressive force of 3,000-6,000 psifor a period of 60-360 minutes and e) removing the composite materialfrom the mold.
 10. The method producing the composite material accordingto claim 9 including the further steps of: f) cutting the compositematerial into a desired size and shape; and g) finishing the surface ofthe composite material.
 11. The composite material according to claim 1wherein the binder is also includes a polymeric binder in the ratio of10-70 parts per 100 natural rubber latex parts.
 12. A composite materialcomprising textile debris and a binder, the textile debris includingfabric scraps, the binder including: natural rubber latex 100 Partssulfur 0-1.0 Parts zinc diethyldithiocarbamat 0-1.0 Parts Lovinox ®, CPL0.1-2.0 Parts zinc oxide (ZnO) 0-5.0 Parts titanium Dioxide (TiO2)1.0-10.0 Parts potassium Laurate (K-laurate) 0.1-1.0 Parts and potassiumhydroxide (KOH) 0.1-1.0 Parts


13. The composite material according to claim 12 wherein the naturalrubber latex comprises 30-65 percent rubber.
 14. The composite materialaccording to claim 12 wherein the binder is also includes a polymericbinder in the ratio of 10-70 parts per 100 natural rubber latex parts.15. A method of producing a composite material according to claim 12comprising the steps of: a) preparing textile scraps from textile debrisby cutting the textile debris into specified sizes; b) mixing thetextile scraps and the binder in a ratio of 10-60% by weight using ablender at a speed of 10-30 revolutions per minute for 5-20 minutes; c)reducing the moisture content of the combined textile scraps and binderto 0-5% using heating process; d) chopping the dried textile scraps andbinder into small pieces into different fiber lengths in the range (a)0.5-1.0 cm (b) 1.0-2.0 cm and (c) 2.0-3.0 cm; e) mixing the choppedingredients (a), (b) and (c) in an appropriate ratios to control thedispersion and adhesion of the fiber with the proportions (a): (b): (c)in the range between 1:1:1 to 1:2:4; f) crosslinking the mixture oftextile scraps and binder in a mold by applying a compressive force of3,000 to 6,000 psi at temperature of 80-180 degrees Celsius for 10-30minutes; g) compressing the cross-linked mixture of textile scraps andbinder in a cold press with a compressive force of 3,000-6,000 psi for aperiod of 60-360 minutes and h) removing the composite material from themold.